General Maintenance Manual for Hydraulic Excavator

CONTENTS
CHAPTER 1
GENERAL CAUTIONS FOR MAINTENANCE WORK
1-1 Correct Work ...........................................................................................................................................................................1-1
1-2 Safety Precautions ..................................................................................................................................................................1-1
1-3 Preparations............................................................................................................................................................................1-1
1-4 Cautions for Disassembly and Reassembly............................................................................................................................1-1
1-5 Cautions for Removal and Installation of Hydraulic Equipment ..............................................................................................1-2
1-6 Cautions for Removal and Installation of Hydraulic Piping......................................................................................................1-2
1-7 Cautions for Handling Seals....................................................................................................................................................1-3
1-8 Correct Installation of Hydraulic Hose.....................................................................................................................................1-3
1-9 Specifications of Hydraulic Hose.............................................................................................................................................1-6
1-10 Air Release of Hydraulic Equipment....................................................................................................................................1-11
CHAPTER 2
TECHNICAL DATA
2-1 Specifications ...................................................................................................................................................................... 2-1-1
2-2 Outline Drawing and Working Area..................................................................................................................................... 2-2-1
2-2-1 Quick coupler ............................................................................................................................................................. 2-2-1
2-2-2 W/O Quick coupler ..................................................................................................................................................... 2-2-2
2-3 Weight List of Main Parts .................................................................................................................................................... 2-3-1
2-4 Lifting Capacity List ............................................................................................................................................................. 2-4-1
2-4-1 SV100......................................................................................................................................................................... 2-4-1
CHAPTER 3
SERVICE STANDARDS
3-1 Machine Performance ......................................................................................................................................................... 3-1-1
3-2 Engine ................................................................................................................................................................................. 3-2-1
3-3 Undercarriage ..................................................................................................................................................................... 3-3-1
3-3-1 Rubber Crawler Specifications................................................................................................................................... 3-3-1
3-3-2 Steel Crawler Specifications....................................................................................................................................... 3-3-2
3-3-3 Common Specifications of Steel & Rubber Crawlers ................................................................................................. 3-3-3
3-4 Controls............................................................................................................................................................................... 3-4-1
3-5 Hydraulic Equipment ........................................................................................................................................................... 3-5-1
3-5-1 Hydraulic Cylinders .................................................................................................................................................... 3-5-1
3-6 Implement ........................................................................................................................................................................... 3-6-1
3-6-1 Front Attachments (Quick Coupler Type)................................................................................................................... 3-6-1
3-6-2 Blade Moving Device.................................................................................................................................................. 3-6-2
3-6-3 Bucket Teeth .............................................................................................................................................................. 3-6-2
3-7 List of Tightening Torque .................................................................................................................................................... 3-7-1
3-7-1 Machine...................................................................................................................................................................... 3-7-1
3-7-2 Engine ........................................................................................................................................................................ 3-7-4
3-7-3 Tightening Torque for General Bolts and Nuts........................................................................................................... 3-7-4

CHAPTER 4
ENGINE
4-1 General ............................................................................................................................................................................... 4-1-1
4-1-1 How to Read This Manual .......................................................................................................................................... 4-1-1
4-1-2 Precautions for Service Work..................................................................................................................................... 4-1-3
4-1-3 Engine External Views .............................................................................................................................................. 4-1-4
4-1-4 Structural Description ................................................................................................................................................ 4-1-4
4-1-5 Exhaust Gas Emission Regulation ............................................................................................................................. 4-1-5
4-2 Troubleshooting .................................................................................................................................................................. 4-2-1
4-2-1 Quick Reference Table for Troubleshooting............................................................................................................... 4-2-1
4-2-2 Troubleshooting by Measuring Compression Pressure ............................................................................................. 4-2-4
4-3 Inspection and Adjustment.................................................................................................................................................. 4-3-1
4-3-1 Oil Inspection.............................................................................................................................................................. 4-3-1
4-3-2 Cooling Water Inspection ........................................................................................................................................... 4-3-1
4-3-3 Inspecting Water Leak from Cooling Water System and Radiator ............................................................................. 4-3-1
4-3-4 Fan Belt Tension Inspection and Adjustment............................................................................................................. 4-3-2
4-3-5 Adjusting the Valve Clearance ................................................................................................................................... 4-3-3
4-3-6 Inspecting the Fuel Injection Valve Injection Pressure and Spray Pattern................................................................. 4-3-5
4-3-7 Fuel Injection Timing Adjustment / Fuel Injection Pump Inspection and Adjustment ................................................. 4-3-9
4-3-8 Sensor Inspection..................................................................................................................................................... 4-3-12
4-3-9 Battery Inspection..................................................................................................................................................... 4-3-13
4-3-10 Adjusting Operation................................................................................................................................................ 4-3-15
4-3-11 Long Storage.......................................................................................................................................................... 4-3-16
4-3-12 Periodic Maintenance Schedule............................................................................................................................. 4-3-17
4-4 Engine Body........................................................................................................................................................................ 4-4-1
4-4-1 Introduction................................................................................................................................................................. 4-4-1
4-4-2 Cylinder Head............................................................................................................................................................. 4-4-2
4-4-3 Gear Train and Camshaft......................................................................................................................................... 4-4-10
4-4-4 Cylinder Block .......................................................................................................................................................... 4-4-15
4-5 Lubrication System.............................................................................................................................................................. 4-5-1
4-5-1 Lubrication System Diagram ...................................................................................................................................... 4-5-1
4-5-2 Trochoid Pump Components...................................................................................................................................... 4-5-1
4-5-3 Disassembly (Reverse the Procedure Below for Assembly) ...................................................................................... 4-5-2
4-5-4 Servicing Points.......................................................................................................................................................... 4-5-2
4-5-5 Parts Inspection and Measurement............................................................................................................................ 4-5-2
4-6 Cooling System ................................................................................................................................................................... 4-6-1
4-6-1 Cooling Water System................................................................................................................................................ 4-6-1
4-6-2 Cooling Water Pump Components............................................................................................................................. 4-6-1
4-6-3 Disassembly (Reverse the Procedure Below for Assembly) ...................................................................................... 4-6-2
4-6-4 Servicing Points.......................................................................................................................................................... 4-6-2
4-7 Fuel Injection Pump / Governor........................................................................................................................................... 4-7-1
4-7-1 Introduction................................................................................................................................................................. 4-7-1
4-7-2 Fuel Injection Pump.................................................................................................................................................... 4-7-1

4-8 Turbocharger : Disassembly, Inspection and Reassembly ................................................................................................. 4-8-1
4-8-1 Structure and Functions ............................................................................................................................................. 4-8-1
4-8-2 Service Standards and Tightening Torque................................................................................................................. 4-8-4
4-8-3 Periodic Inspection Procedure ................................................................................................................................... 4-8-5
4-8-4 Disassembly Procedure ............................................................................................................................................. 4-8-9
4-8-5 Washing and Inspection procedure.......................................................................................................................... 4-8-12
4-8-6 Reassembly Procedure ............................................................................................................................................ 4-8-16
4-8-7 Handling after Disassembly and Reassembly.......................................................................................................... 4-8-19
4-8-8 Troubleshooting........................................................................................................................................................ 4-8-20
4-9 Starting motor...................................................................................................................................................................... 4-9-1
4-9-1 Specifications ............................................................................................................................................................. 4-9-1
4-9-2 Configuration Drawing................................................................................................................................................ 4-9-2
4-9-3 Troubleshooting.......................................................................................................................................................... 4-9-3
4-9-4 Component Names and Disassembly Procedure ...................................................................................................... 4-9-4
4-9-5 Disassembly Procedure ............................................................................................................................................. 4-9-5
4-9-6 Inspection and Maintenance ...................................................................................................................................... 4-9-7
4-9-7 Assembly.................................................................................................................................................................. 4-9-11
4-9-8 Adjustment ............................................................................................................................................................... 4-9-12
4-9-9 Service Standards.................................................................................................................................................... 4-9-13
4-10 Alternator......................................................................................................................................................................... 4-10-1
4-10-1 Specifications ......................................................................................................................................................... 4-10-1
4-10-2 Section View........................................................................................................................................................... 4-10-2
4-10-3 Troubleshooting...................................................................................................................................................... 4-10-3
4-10-4 Parts Names and Disassembly Procedure............................................................................................................. 4-10-4
4-10-5 Inspection and Overhaul ........................................................................................................................................ 4-10-7
4-10-6 Assembly.............................................................................................................................................................. 4-10-11
4-10-7 Service Standards................................................................................................................................................ 4-10-12
4-10-8 Performance Test................................................................................................................................................. 4-10-13
4-11 Special Service Tools...................................................................................................................................................... 4-11-1
4-11-1 Special Tools.......................................................................................................................................................... 4-11-1
4-11-2 Measuring Instruments........................................................................................................................................... 4-11-3
4-12 Service Standards........................................................................................................................................................... 4-12-1
4-12-1 Engine Turning....................................................................................................................................................... 4-12-1
4-12-2 Engine Body........................................................................................................................................................... 4-12-2
4-12-3 Lubricating Oil System (Trochoid Pump)................................................................................................................ 4-12-6
4-12-4 Tightening Torques for Main Parts......................................................................................................................... 4-12-7
CHAPTER 5
HYDRAULIC SYSTEM
5-1 Outline (Quick Coupler Type).............................................................................................................................................. 5-1-1
5-1-1 Control Valve Operation ............................................................................................................................................. 5-1-3
5-1-2 Additional Operation of Control Valve ........................................................................................................................ 5-1-4
5-2 Hydraulic Circuit Schematic ................................................................................................................................................ 5-2-1

5-3 Circuit Operation ................................................................................................................................................................. 5-3-1
5-3-1 Boom.......................................................................................................................................................................... 5-3-1
5-3-2 Arm............................................................................................................................................................................. 5-3-2
5-3-3 Bucket ........................................................................................................................................................................ 5-3-3
5-3-4 Swing.......................................................................................................................................................................... 5-3-4
5-3-5 Boom Swing ............................................................................................................................................................... 5-3-5
5-3-6 Blade .......................................................................................................................................................................... 5-3-6
5-3-7 Travel ......................................................................................................................................................................... 5-3-7
5-3-8 Non-deviation Travel (with Boom, Arm, Bucket or Boom Swing Operation) .............................................................. 5-3-8
5-3-9 Simultaneous Operation of Boom Up and Arm Retract.............................................................................................. 5-3-9
5-3-10 Simultaneous Operation of Boom Up and Bucket.................................................................................................. 5-3-10
5-3-11 Simultaneous Operation of Boom Up and Swing ................................................................................................... 5-3-11
5-3-12 Simultaneous Operation of Arm and Bucket .......................................................................................................... 5-3-12
5-3-13 Hydraulic P.T.O...................................................................................................................................................... 5-3-13
5-3-14 Travel Alarm........................................................................................................................................................... 5-3-14
5-3-15 Quick Coupler......................................................................................................................................................... 5-3-15
5-3-16 2nd P.T.O............................................................................................................................................................... 5-3-16
5-4 Pressure Adjustment........................................................................................................................................................... 5-4-1
5-4-1 Relief Valves .............................................................................................................................................................. 5-4-1
5-4-2 Swing Brake Valve ..................................................................................................................................................... 5-4-3
5-4-3 Cut-off Valve............................................................................................................................................................... 5-4-4
CHAPTER 6
HYDRAULIC EQUIPMENT
6-1 Hydraulic Pump................................................................................................................................................................... 6-1-1
6-2 Control Valve....................................................................................................................................................................... 6-2-1
6-2-1 Hydraulic Circuit Schematic and Parts Name ............................................................................................................ 6-2-1
6-2-2 Operation of Each Spool Section ............................................................................................................................... 6-2-2
6-2-3 Relief Valves ............................................................................................................................................................ 6-2-27
6-3 Pilot Valve ........................................................................................................................................................................... 6-3-1
6-4 Swing Motor ........................................................................................................................................................................ 6-4-1
6-5 Travel Motor ........................................................................................................................................................................ 6-5-1
6-5-1 Specifications ............................................................................................................................................................. 6-5-1
6-5-2 Model Labeling ........................................................................................................................................................... 6-5-1
6-5-3 External Dimensions .................................................................................................................................................. 6-5-2
6-5-4 Basic Configuration and Drawing ............................................................................................................................... 6-5-3
6-5-5 Operating Description................................................................................................................................................. 6-5-6
6-5-6 Troubleshooting........................................................................................................................................................ 6-5-12
6-5-7 Disassembly............................................................................................................................................................. 6-5-14
6-5-8 Service Preparations ................................................................................................................................................ 6-5-31
6-5-9 Assembly.................................................................................................................................................................. 6-5-33
6-5-10 Performance Congirmation Test ............................................................................................................................ 6-5-48
6-5-11 Clearance Adjustment Parts Dimensions Table..................................................................................................... 6-5-49
6-6 Pilot Check Valve (Quick Coupler Type)............................................................................................................................. 6-6-1

CHAPTER 7
ADJUSTMENT AND REPAIR
7-1 Electric Equipment of the Machine...................................................................................................................................... 7-1-1
7-1-1 Parts Layout of Electrical Equipment ......................................................................................................................... 7-1-1
7-1-2 Monitor and Alarm Systems ....................................................................................................................................... 7-1-4
7-1-3 Wiring Diagram........................................................................................................................................................... 7-1-7
7-1-4 Stop Motor Operation................................................................................................................................................. 7-1-9
7-1-5 Removal and Reinstallation of Engine ..................................................................................................................... 7-1-11
7-1-6 Removal and Reinstallation of Starter Motor............................................................................................................ 7-1-21
7-1-7 Removal and Reinstallation of Radiator................................................................................................................... 7-1-22
7-1-8 Removal and Reinstallation of Fan Belt and Compressor Driving Belt .................................................................... 7-1-25
7-1-9 Removal and Reinstallation of Fuel Injection Pump................................................................................................. 7-1-26
7-2 Undercarriage ..................................................................................................................................................................... 7-2-1
7-2-1 Outline........................................................................................................................................................................ 7-2-1
7-2-2 Compatibility of Main Parts......................................................................................................................................... 7-2-1
7-2-3 Points of Reassembly (Rubber Crawler Type) ........................................................................................................... 7-2-2
7-2-4 Points of Reassembly (Steel Crawler Type)............................................................................................................... 7-2-3
7-2-5 Removal and Reinstallation of Crawler ...................................................................................................................... 7-2-4
7-2-6 Disassembly and Reassembly of Steel Crawler......................................................................................................... 7-2-7
7-2-7 Disassembly and Reassembly of Front Idler.............................................................................................................. 7-2-9
7-2-8 Disassembly and Reassembly of Track Roller......................................................................................................... 7-2-11
7-2-9 Installation of Floating Seal ...................................................................................................................................... 7-2-13
7-2-10 Disassembly and Reassembly of Carrier Roller..................................................................................................... 7-2-14
7-3 Controls............................................................................................................................................................................... 7-3-1
7-3-1 Control Train............................................................................................................................................................... 7-3-1
7-3-2 Mechanical Control Linkage ....................................................................................................................................... 7-3-2
7-3-3 Adjustment of Travel Levers....................................................................................................................................... 7-3-4
7-3-4 Adjustment of Boom Swing Pedal .............................................................................................................................. 7-3-5
7-3-5 Adjustment of Blade Lever ......................................................................................................................................... 7-3-5
7-3-6 Adjustment of Lock Lever........................................................................................................................................... 7-3-6
7-3-7 Adjustment Procedure of P.T.O. Pedal ...................................................................................................................... 7-3-7
7-3-8 Adjustment Procedure of P.T.O. Pedal Lock.............................................................................................................. 7-3-7
7-3-9 Adjustment of Accelerator Lever ................................................................................................................................ 7-3-8
7-4 Swing Bearing ..................................................................................................................................................................... 7-4-1
7-4-1 Removal and Reinstallation of Swing Bearing ........................................................................................................... 7-4-1
7-5 Hydraulic Equipment ........................................................................................................................................................... 7-5-1
7-5-1 Removal and Reinstallation of Hydraulic Pump ......................................................................................................... 7-5-1
7-5-2 Removal and Reinstallation of Control Valve ............................................................................................................. 7-5-5
7-5-3 Removal and Reinstallation of Swing Motor............................................................................................................... 7-5-8
7-5-4 Removal and Reinstallation of Swivel Joint.............................................................................................................. 7-5-10
7-5-5 Disassembly and Reassembly of Swivel Joint ......................................................................................................... 7-5-13
7-5-6 Disassembly and Reassembly of Hydraulic Cylinders ............................................................................................. 7-5-16
7-5-7 Hydraulic Oil Tank.................................................................................................................................................... 7-5-20
7-5-8 Piping Layout............................................................................................................................................................ 7-5-26

7-6 Implement ........................................................................................................................................................................... 7-6-1
7-6-1 Removal and Reinstallation of Implement.................................................................................................................. 7-6-1
7-6-2 Quick Coupler............................................................................................................................................................. 7-6-9
7-7 Air Conditioner .................................................................................................................................................................... 7-7-1
7-7-1 Removal and Reinstallation of Air Conditioner........................................................................................................... 7-7-1
CHAPTER 8
PERIODIC INSPECTION AND SERVICING
8-1 List of Periodic Inspection and Servicing.................................................................................................................................8-1
CHAPTER 9
FUEL, LUBE OIL AND GREASE RECOMMENDED
9. Fuel, Lube Oil and Grease Recommended...............................................................................................................................9-1
CHAPTER 10
TROUBLESHOOTING
10-1 Non-breakdowns ............................................................................................................................................................. 10-1-1
10-1-1 Natural Release of Bucket...................................................................................................................................... 10-1-1
10-1-2 Discontinuous Arm Movement ............................................................................................................................... 10-1-1
10-1-3 Thermal Shock of Travel Motor.............................................................................................................................. 10-1-2
10-1-4 Elongation of Boom Swing Cylinder on 68 degrees Swing .................................................................................... 10-1-3
10-1-5 Time Lag on Travel Speed Switching..................................................................................................................... 10-1-4
10-1-6 Fluctuation in Oil Level of Hydraulic Oil Tank due to Temperature Change .......................................................... 10-1-5
10-1-7 Operation of Quick Coupler Cylinder...................................................................................................................... 10-1-6
10-2 Troubleshooting .............................................................................................................................................................. 10-2-1
10-2-1 Machine and Engine............................................................................................................................................... 10-2-1
10-2-2 Electrical Equipment on Panel ............................................................................................................................. 10-2-23
CHAPTER 11
REFERENCE DATA
11-1 Specifications for Attachment..............................................................................................................................................11-1

CHAPTER 1
GENERAL CAUTIONS FOR MAINTENANCE WORK
1-1 Correct Work............................................................................................1-1
1-2 Safety Precautions...................................................................................1-1
1-3 Preparations ............................................................................................1-1
1-4 Cautions for Disassembly and Reassembly ............................................1-1
1-5 Cautions for Removal and Installation of Hydraulic Equipment...............1-2
1-6 Cautions for Removal and Installation of Hydraulic Piping ......................1-2
1-7 Cautions for Handling Seals ....................................................................1-3
1-8 Correct Installation of Hydraulic Hose .....................................................1-3
1-9 Specifications of Hydraulic Hose .............................................................1-6
1-10 Air Release of Hydraulic Equipment ...................................................1-11

1. GENERAL CAUTIONS FOR
MAINTENANCE WORK
1-1 4990505
1. General Cautions for Maintenance Work
1-1 Correct Work
Correct work means the quickest possible completion of according to the correct procedures and the specified stan-
dards.
It is important when conducting certain operations always to bear in mind the equipment, tools, gauges, materials, oil
and grease, etc. that you must have ready, as well as items to be checked, adjusted, or disassembled, and cautions
to watch out for.
1-2 Safety Precautions
(1) Never attempt servicing while engine is running or immediately after stopping operation.
(2) Wear work cloths, safety shoes and helmet.
(3) Check the equipment and tools before use. Especially, be sure to check the crane, lifting equipment and tools.
(4) When working together with other persons, allocate everyone's share of job, arrange the signals and act in con-
cert with the other persons.
(5) The operation of the crane and slinging work must be performed by qualified persons.
(6) Do not enter or pass under the raised load.
(7) Lift and support the massive parts by crane before removing the installation bolts.
(8) Disconnect cables from battery before repairing the electric system.
(9) Remove the battery when welding the machine.
1-3 Preparations
(1) Check the service record of the machine. (That is, check how many months or hours the machine has been
used since the preceding overhaul, what was the trouble then and what parts were replaced.)
(2) Have all servicing tools ready, i.e., tools, measuring devices (which have received periodic maintenance), con-
tainers, oil & grease, etc.
(3) Have the service literature (operation manual, parts catalog, etc.) ready.
1-4 Cautions for Disassembly and Reassembly
(1) Clean the machine before disassembly.
(2) Check and record the condition of the machine before disassembly :
• Model, machine number, operation hours
• Reasons for repair, history of repair
• Contamination of filters
• Fuel and oil condition
• Damage to parts, etc.
(3) Place alignment marks on the necessary parts to facilitate reassembly.
(4) Clean all the removed parts and new replacement parts and put them in order.
(5) Use new seals, split pins, etc. for reassembly.

MAINTENANCE WORK
1-2 4990505
(6) Keep the parts apt to be damaged by water or oil apart from the oily or wet parts.
e.g.: Electrical parts, rubber parts, V-belts, etc.
(7) Use the jig for press-fitting the bearings, bushes and oil seals. When
using a hammer, use a pad block.
(8) Clean the joint surface of all parts and keep them free from dust.
(9) Wind the sealing tape securely, leaving a space of one or two
threads from the tip of the male screw. The tape should have an
overlap of about 0.4 in. (10 mm).
1-5 Cautions for Removal and Installation of Hydraulic Equipment
(1) Check that the hydraulic oil temperature is low enough.
(2) Release air from the hydraulic tank to prevent the hydraulic oil from flowing out.
(3) Be sure to plug open the ends of hydraulic components to prevent dust from entering.
(4) Be sure to wipe hydraulic oil from the hydraulic components so that it will not be mistaken for an oil leak.
(5) Take care not to damage the plating on the cylinder rod.
(6) Remove or install cylinders with rods fully retracted.
(7) Be sure to release air after installing the hydraulic cylinders.
• Run the engine at a low speed. Extend and retract the cylinders 4 to 5 times up to 2.0 to 3.9 in. (50 to 100 mm)
from the end of the stroke. Then, fully extend and retract.
(8) Be sure to pressurize the hydraulic tank after installing the hydraulic components (in the case of the sealed
hydraulic tank). Otherwise, hydraulic pumps might suffer cavitation and their life will be shortened.
• To pressurize the hydraulic tank, fully extend each cylinder and tighten the oil filter port plugs.
1-6 Cautions for Removal and Installation of Hydraulic Piping
(1) Installation of hydraulic hose
Take care not to twist the hoses. (Judge whether or not the hose is twisted
by the hose mark.) For hoses with a metal fitting, use two wrenches to pre-
vent twisting.
Use one to fix the hose, and the other to tighten the fitting to the specified
tightening torque. Carefully check that the hoses do not come in contact after
tightening. If any contact is found, correct it or use tubes.
(2) When installing hoses, first tighten to the specified torque and then loosen
them a little. Then retighten to the specified torque.
• Break in the installed parts before tightening (except those using seal tapes).
(3) When installing pipes, turn the nuts more 1/4 to 1/2 turn after they reach the sharp torque rise point.
(4) When installing or removing hoses, use two wrenches, one to fasten the hose and the other to tighten or loosen
the hose to prevent twisting.
(5) Check for oil leakage by applying max. pressure 5 to 6 times after attaching hydraulic hoses or pipes.
One and a half threads
Sealing tape
Metal fitting
Hose
Fixed side
Pipe or
connector

MAINTENANCE WORK
1-3 4990505
1-7 Cautions for Handling Seals
(1) Clean out grooves of O-rings. Remove burrs or dust if any.
(2) Take care not to twist O-rings. Correct by your finger if it is twisted.
(3) Take care not to damage seals when inserting.
(4) Handling of floating seals :
• Completely wipe off all the oil from the O-ring and housing after detaching the floating seals.
• Before installing, apply a little gear oil to the matching face of the housing.
• Turn the seals two or three times after installation to break them in.
(5) Apply grease to the lip of the oil seals to prevent wear.
1-8 Correct Installation of Hydraulic Hose
In order to mount the hydraulic hose most effectively and economically, observe the following cautions.
(1) When a hose is used at the minimum bending radius, use elbows to avoid sharp bending.
(2) To prevent twisting, the hose should be bent in the same direction as it moves.
Burrs
Dust
Grease
Not good Good
Not good Good

MAINTENANCE WORK
1-4 4990505
(3) When the hose is pressurized, the hose length varies slightly at the bend. Allow this change to occur and do not
try to fasten the bend.
(4) It is necessary for the hose to have ample slackness for elongation and contraction, because its length will
change by +2 % to -4 % when used at high pressure.
(5) Use the proper adapters, not pipes, in order to reduce the number and length of joints and improve the external
appearance.
(6) Use an elbow to prevent excessive twisting or bending of the hose.
(7) Use adapters to make the hose as straight as possible. The outside appearance can be improved by avoiding
the use of hoses that are too long.
Not pressurized
When pressurized
Not good
Good
Not good Good
Not good Good
Not good Good

MAINTENANCE WORK
1-5 4990505
(8) The hose should be slightly longer than is absolutely necessary. The extra allows smoother movement of the
hose and prevents sharp bending.
(9) When a bent hose is attached to two different planes, fix as shown in the diagram to prevent twisting.
(10) Use the marking on the hose as a guide to prevent twisting during installation.
Twisting of metal fitting with union nuts should be with a wrench on the hexagonal parts.
Not good Good
Not good Good
Not good
Hose mark Hose mark
Good

MAINTENANCE WORK
1-6 4990505
1-9 Specifications of Hydraulic Hose
Two types of hydraulic hoses are used in Yanmar Construction Machinery : the standard parts specified in the Yan-
mar Industrial Standards (YIS) and special parts for the respective models. Specifications of the hydraulic hoses can
be known by the code number or part descriptions as explained below. (For the parts number, please refer to our
Parts Catalog.)
(1) Yanmar Standard Type
The part code consists of 11-digit numbers :
Hose material code
Hose type code
Fittings combination code
Nominal length code
Nominal dia. code
Description
Part code No.
Hose material
Rubber hose
(High pressure type)
Rubber hose
(Medium pressure type)
Plastic hose
(High pressure type)
Hose material Type of hose Hose dia. Hose length Combination
of fittings
2320
2327
2325
1
1
3
2
2
1
1
(SAE J517,100R1)
(SAE J517,100R2)
(SAE J517,100R7)
(SAE J517,100R7)
(SAE J517,100R6)
02
03
04
02
03
04
03
04
02
03
04
05
06
10
12
14
Unit : cm 4
5
6
1
1
4
4
5
5
7

MAINTENANCE WORK
1-7 4990505
1) Type of Hose (Hose Dia. & Recommended Working Pressure)
2) Total Length of Hose [Unit : in. (cm)]
3) Hose Dia. (Unit : inch)
Note :
Please note that these code numbers are different from those for the equivalent diameters for special parts on the
next page.
Type of hose Hose dia.
Inner dia.
[in. (mm)]
Outer dia.
[in. (mm)]
Working
pressure
[PSI (MPa)]
1
(SAE J517, 100R1)
02 0.25 (6.3) 0.53 (13.5) 2489 (17.2)
03 0.37 (9.5) 0.69 (17.5) 1991 (13.7)
04 0.50 (12.7) 0.81 (20.6) 1564 (10.8)
2
(SAE J517,100R7)
02 0.25 (6.3) 0.59 (15.1) 4266 (29.4)
03 0.37 (9.5) 0.75 (19.1) 3484 (24.0)
04 0.50 (12.7) 0.87 (22.2) 2986 (20.6)
1
(SAE J517, 100R6)
02 0.25 (6.3) 0.49 (12.5) 2986 (20.6)
03 0.37 (9.5) 0.65 (16.6) 2489 (17.2)
04 0.50 (12.7) 0.81 (20.7) 1991 (13.7)
2
(SAE J517,100R7)
03 0.37 (9.5) 0.68 (17.2) 2986 (20.6)
04 0.50 (12.7) 0.84 (21.4) 2986 (20.6)
1
(SAE J517,100R6)
02 0.25 (6.3) 0.50 (12.7) 427 (2.9)
03 0.37 (9.5) 0.63 (15.9) 427 (2.9)
04 0.50 (12.7) 0.78 (19.8) 427 (2.9)
05 0.63 (15.9) 0.91 (23.0) 427 (2.9)
06 0.75 (19.0) 1.25 (31.8) 427 (2.9)
10 1.00 (25.4) 1.50 (38.1) 427 (2.9)
12 1.25 (31.8) 1.75 (44.5) 427 (2.9)
14 1.50 (38.1) 2.04 (51.9) 427 (2.9)
02....1/4'' 05....5/8'' 12....1 1/4''
03....3/8'' 06....3/4'' 14....1 1/2''
04....1/2'' 10....1
L L L
3 digit indication in cm. (Example) Nominal length 065 : Full length 25.6 in. (65 cm)

MAINTENANCE WORK
1-8 4990505
4) Combination of Fitting
Note :
All the hoses with fittings other than those listed above are special parts.
Code No.
Fitting
type
1 A·B
3 A·E
4 B·B
5 B·C
6 B·E
7 B·D
List of pipe threads
Symbol Name
G (PF)
Straight pipe
thread
R (PT)
Male taper pipe
thread
Rc (PT)
Female taper
pipe thread
(Example) Part code 2 3 2 0 2 0 3 0 8 5 5
Rubber hose, high pressure type
SAE J517, 100R2
Nominal dia., 3 / 8"
Hose length, 33.5 in. (85 cm)
Straight pipe thread G (PF) with
male 30 degrees seat and 90 degrees bent type.
Straight pipe thread G (PF) with
male 30 degrees seat
A
Taper pipe thread
R (PT)
D
60 degrees bent type.
Straight pipe thread
G (PF) with male 30
degrees seat
B
G (PF) with male 30
degrees seat
E
G (PF) with male 30
degrees seat
C
G (PF) with male 30
degrees seat
R(PT)
G(PF)
G(PF)
G(PF)
G(PF)

MAINTENANCE WORK
1-9 4990505
(2) Special Parts
The example hose, P 2 06 AB 075 W stands for :
2 3 4 5 6 7
2 Material : Plastic
3 Working pressure : 2489 to 2986 PSI (17.2 to 20.6 MPa)
4 Nominal dia. : 3 / 8"
5 Fitting type : Taper pipe thread R (PT) and straight pipe thread G (PF) with male 30 degrees seat.
6 Length : 29.5 in. (75 cm)
7 Hose protector : Coil spring
Description ..................... Hose P 2 06 AB 075 W
1 Part name
3 Recommended
working pressure
PSI(Mpa)
Over 2986 (20.6) ..................... 1
2489 to 2986 (17.2 to 20.6) ..... 2
1991 to 2489 (13.7 to 17.2) ..... 3
1564 to 1991 (10.8 to 13.7) ..... 4
995 to 1564 (6.9 to 10.8) ......... 5
427 to 995 (2.9 to 6.9) ............. 6
213 to 427 (1.5 to 2.9) ............. 7
Below 213 (1.5) ....................... 8
4 Nominal dia. (inch)
1 / 8" ......................... 02
3 / 16" ....................... 03
1 / 4" ......................... 04
3 / 8" ......................... 06
1 / 2" ......................... 08
5 / 8" ......................... 10
3 / 4" ......................... 12
1" .............................. 16
5 Combination of fitting
Fitting type Code
Taper pipe
thread R (PT)
A
Straight pipe
thread G (PF)
with male 30
degrees seat
B
90 degrees
bent type.
Straight pipe
thread G (PF)
with male 30
degrees seat
C
Without fitting Y
For the combination of fitting,
refer to the list on the following
page.
6 Total length
(Unit : cm)
Symbol
G (PF)
R (PT)
Rc (PT)
Name
Male taper pipe thread
Female taper pipe thread
List of pipe threads
1 2 8
7
6
5
4
3
2 Hose material
Rubber hose ........... G
Wear-resistant high
pressure rubber
hose ....................... H
Plastic hose ............ P
8 Other accessories
No accessories...Blank
O-ring ....................... 1
7 Hose protector
Coil spring ............... W
Coil tube .................. S
Wire braid ................ B
Tube (Rubber) .......... R
Tube (Vinyl) .............. V
Sponge rubber ......... P
Hose cover ............... K
No protection ..... Blank
90
30
G(PF)
R(PT)
30
G(PF)

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MAINTENANCE WORK
1-10 4990505
5 Combination of fitting
Fitting type Code Fitting type Code
Taper pipe thread R (PT) A
UNF thread with female
37 degrees seat
P
Straight pipe thread G
(PF) with male 30
degrees seat
B
37 degrees seat
Q
(PF) with male 30
degrees seat
C
37 degrees seat
R
(PF) with male 30
degrees seat
D
UNF, thread with O-ring
groove
S
(PF) with male 30
degrees seat
E
One-touch fitting (male)
T
(PF) with male 30
degrees seat
F
90 degrees elbow straight
pipe thread male 30
degrees seat
V
O-ring flange type G
90 degrees bent O-ring
flange type H
Eyejoint with O-ring
groove
W
45 degrees bent O-ring
flange type J
Straight pipe thread,
female 30 degrees seat
with O-ring groove
K
Straight pipe thread with
jam nut female 30
degrees seat X
(PF) with male 30
degrees seat
L
90 degrees elbow straight
pipe thread with gauge
port plug male 30
degrees seat
Z
Taper pipe thread NPTF M
UNF, thread with female
37 degrees seat N
Without fitting Y
Note :
According to the combination of bending or elbow fittings, some
hoses require drawings or original hoses to locally manufacture.
R(PT)
UNF
G PF
UNF
G PF
UNF
G PF
UNF
O-ring
G PF
O-ring
G PF
G PF
O-ring groove
G PF
G PF
PF nut
G PF G PF
Gauge port
NPTF
UNF

MAINTENANCE WORK
1-11 4990505
1-10 Air Release of Hydraulic Equipment
When operating the machine after disassembly or parts replacement of the hydraulic equipment, piping, etc., be
sure to release air from the hydraulic system. This is necessary to prevent seizure and cavitation of the hydraulic
equipment. If the air is left in the hydraulic system, the air is compressed or expanded depending on the load, having
an adverse effect on the smooth operation of the hydraulic equipment and shortening the service life.
1. Air Release of Variable Displacement Piston Pumps
1) Put a Specified Quantity of Hydraulic Oil Into the Hydraulic Oil Tank.
Note :
1. Set the machine at the oil level check position.
2. Refer to the hydraulic oil supply procedure for how to put hydraulic oil into the tank.
2) Keep the Oil Supply Cap of the Hydraulic Oil Tank Removed.
3) Install the Air Bleeder Hose onto the Bleeder Valve
and Loosen the Bleeder Valve Half a Turn. (Inside
Diameter of the Hose : 0.20 in. [5 mm])
Note :
Since the top end of the bleeder valve is acting as a
seat surface, the air is released only by loosening the
bleeder valve.
4) Check that All the Air has been Released from the
Bleeder Valve.
5) Tighten the Bleeder Valve, Remove the Hose and
Install the Cap on the Bleeder Valve.
2. Air Release of Each Hydraulic Component
Run the engine at medium speed and activate the respective circuits for about 10 to 15 minutes.
3. Air Release of Hydraulic Cylinders
1) Set the Engine Speed at Low Idling Range.
2) Extend and Retract the Cylinder Up to 1.97 to 3.9 in. (50 to 100 mm) from Each Stroke End Slowly 4 or 5
Times.
Note :
The extension and retraction stroke is up to 1.97 in. (50 mm) from each stroke end for the blade cylinder.
3) Then, Fully Extend and Retract the Cylinder 3 or 4 Times.
Bleeder valve Width across flats : 0.40 in. (10 mm)
Tightening torque 3.61 to 5.06 ft·lbf (4.9 to 6.7 N·m)
Drain container
Hose
Bleeder valve
Retraction stroke end
1.97 to 3.9 in.
(50 to 100 mm)
1.97 to 3.9 in.
(50 to 100 mm)
Retraction stroke end

CHAPTER 2
TECHNICAL DATA
2-1 Specifications....................................................................................... 2-1-1
2-2 Outline Drawing and Working Area ..................................................... 2-2-1
2-2-1 Quick coupler............................................................................. 2-2-1
2-2-2 W/O Quick coupler..................................................................... 2-2-2
2-3 Weight List of Main Parts..................................................................... 2-3-1
2-4 Lifting Capacity List.............................................................................. 2-4-1
2-4-1 SV100 ........................................................................................ 2-4-1

2. TECHNICAL DATA
2-1-1 4990505
2. Technical Data
2-1 Specifications
Item Unit SV100
Main specifications of machine
Dimensions
Overall length (Transportation position) in. (mm) 253.1 (6430)
Cabin
Overall height
Transportation position in. (mm) 111.4 (2830)
Traveling position in. (mm) 111.4 (2830)
Overall width Full machine width in. (mm) 91.3 (2320)
Canopy
Overall height
Transportation position in. (mm) -
Traveling position in. (mm) -
Overall width Full machine width in. (mm) -
Tumbler center distance (steel / rubber) in. (mm) 92.7 (2354) / 93.0 (2362)
Track gauge in. (mm) 73.6 (1870)
Minimum ground clearance in. (mm) 17.7 (450)
Traveling performance
Travel
speed
Steel crawler
Low speed (Forward/Reverse) MPH (km/hr) 1.55 (2.5)
High speed (Forward/Reverse) MPH (km/hr) 2.80 (4.5)
Rubber crawler
Low speed (Forward/Reverse) MPH (km/hr) 1.62 (2.6)
High speed (Forward/Reverse) MPH (km/hr) 2.92 (4.7)
Permissible water depth limit in. (mm) -
Work performance
Bucket
Width (Standard) *including side cutter in. (mm) 31.5 (800)
[Standard. JIS heaped capacity] cu.ft. (cu.m) 10.6 (0.30)
Number of teeth / Installation method pcs. 4 / rubber pin lock type
Maximum
digging
depth
With blade raised in. (mm) 183.1 (4650)
With blade on the ground in. (mm) 192.9 (4900)
Maximum depth of vertically digging in. (mm) 165.4 (4200)
Maximum dumping height in. (mm) 195.3 (4960)
Minimum front swing radius (with boom in front) in. (mm) 96.1 (2440)
Minimum front swing radius
(at 90 degrees right boom swing)
Cabin in. (mm) 79.1 (2010)
Canopy in. (mm) -
Rear end swing radius in. (mm) 52.4 (1330)
Boom swing angle
Cabin
Left degrees 68
Right degrees 68
Canopy
Left degrees -
Right degrees -
Maximum digging force
Bucket lbs. (k•N) 12216 (54.3)
Arm lbs. (k•N) 9658 (43.0)

General Maintenance Manual for Hydraulic Excavator

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General Maintenance Manual for Hydraulic Excavator